Homemade CNC Plasma - hypertherm, Mesa, gear drives, nema 34.

So i have done the calculator, and fudged the numbers to get the voltage back around 0v

Confirm - 1/32 setting on board.
Confirm - Plasma is set to 20:1.
Confirm - torch starts and the light on the THCAD 10 flashes faster.

Well the THCAD data is in hal so you are nearly there
what have you got set for 
Voltage scale and voltage offset here?
linuxcnc.org/docs/stable/html/plasma/qtp...lasma:parameters-tab
Maybe PCW can see something missing on the night shift...

Yes, this can't be right:

setp hm2_7i96.0.encoder.00.scale -1

It also looks almost like the velocity is random numbers
which suggests a wiring error or 7I96 encoder input 'A' not
jumpered for differential mode.

Realised that T17 didn't have the input on the encoder set for arc ok, T18 does.

Double checked wiring, 99% sure it's all correct.

 
 
 

Well, that looks right.
PCW, the encoder details seem correct as they have been listed in an earlier post
I don't think I can help further..
 

assuming the plasma firmware is installed and it is a 7i96, The encoder pins are on TB2 as follows